Process of making cement.



R. W. LESLEY & H. S. SPACKMAN.

PROCESS 0E MAKING CEMENT.

APPLIoATIoN FILED ooT.4, 1906.

929, 145'. E E A Patented July 27, 19

2 SHEETS-SEEE UNITED sTATEs PATENT OFFICE.

ROBERT W. lLESLEY, OF HAVERFORD, AND HENRY S. SPACKMAN, OF ARDMORE, PENNSYL- VANIA, ASSIGNORS TO' PINE STREET PATENTS COMPANY, A CORPORATION OF NEW JERSEY.

PROCESS 0F MAKING CEMENT.

Specification of Letters Patent.

Patented July 27, 1909.

Applicatonled October 4, 1906. Serial No. 337,347.

Pennsylvania, both citizens of the United.

States, have invented certain new and useful Improvements in Processes of Making Cement, of which the following is a specification, reference being had to the accompanying drawings, forming a part hereof.

In the manufacture of lortland and other commercial cements, the raw materials which maybe mixtures of clay or shite with limeslmie, marl, etc., or may rbe cement rock, with or without adinixtures of limestone, shite, etc., are first dried and then ground to a flour-like fineness, say so that 90 per cent. will pass through a hundred mesli sieve. This fine material, in the practice usual in this country is then passed downward through aiotary inclined kiln as a traveling stream against a current of flame and flame gases coming from {iameproducing means in the mouth of the kiln whereby the matei rial is calcined, or freed from earbonic acid gas (carbon dioxid) and is then brought to incipient vitrification or` clinke'ring. The clinker produced is nally ground to an impalpablc powder to form ordinary commercial cement.

The crushing and pulverizing of the raw materials require Vextensive machines and the expenditure of a great amount of power. Moreover, about one-third of the Weight and bulk of the raw materials is made up of cai'- bnic acid gas and moisture which are eliminated in the calcining stage. The useless Vweight and bulk must be handled through all the stages of treatment up to the actual clinkering. The great amount .of `power consumed in handling so much unnecessary weight and in pulverizing the raw mate rials which are then in their hardest condition, forms a large feature in the cost of producing cement. Hard, dense limestones and cement rocks are usually preferred because of their density since they occupy less space in the kiln and render a larger output possible; and these lhard rocks are of course expensive to comminute to a llourlike lineness by di' vgrinding methods.

It 'has been proposed to calcinc oi' partiall)v ealcine the raw materials in a vertical kiln, driving ott' the carbonic acid gas and the moisture and rendering the further reduction of the materials easier, then to grind to powder and treat in a rotary kilnfand finally to pulverize the clinker as usual, but the process as carried out with avertical kiln -is not and cannot be continuous, involv- 'ing practically a double manufacturing process and moreover the expenditure lof time and labor involved in the use of a vertical kiln is so great as to prohibit the coinmercial manufacture of cement by this double recess.

Fine grinding at some stage in the operation is required to insure that in the clinkering stage the cement-forming ingredients shall be uniformly and ytliorou lily admixed in the form of excessively ne powders. Since in the clinkering the fusion or sintering isnot allowed to go Very far, the reaction of these bodies on each other is largely superficial and'if a particle of clay or lime, for instance, be comparatively coarse it will only be converted superficially, retaininga coieof unconverted material. It is'tlieretore absolutely necessary that in clinkering the cliiikermaking bodies shall be presented to each other in the form of intimately and homogeneously admixed, impalpably fine powders. But it is not necessary that this tinegrinding be performed on the raw materials prior to their entranceinto the kiln system; it is, on the other hand, desirable that this grinding be postponed to an inter mediate stage of the operation after the materials have lost their original hardness.

It is the object of this invention to improve the process of manufacturingcement so that the manufacture can be carried on as a continuous process without intermission from beginning to end and without requiring the manual handling of materials at any stage, and by a method which shall enable much of the heavy and expensive crushing and grinding machinery to be dispensed with,-and shall permit much or all of the unnecessary weight of carbonio acid gas and moisture to bel eliminated at an early stage in the process of-manufacture, thereby en'- abliiig the treatment of much more material per time `unit in a given kiln. There is a maximum thickness of the layer of traveling material Which can be passed through a rotary kiln and with ya material thus calcined the output of clinker increased.

In accordance with the invention, the raw material, Whether limestone or cement rock or a mixture of both, is first crushed coarsely, is then immediately and progressivel calcined toa degree sufficient to drive o carbonic acid gas and moisture, thereby rendering the material softer, porous and friable, is reduced to powder, and finally is further heated. to a degree suliicient to effect combination of the constituents or clinkering, al1 in a continuous and progressive process, each stage directly succeeding another upon the cement material without intermission. lThe cement clinker which is produced by the process may be pulverized immediately or stored as clinker to be pulverized later.

The invention will be more fully explained hereinafter With reference to the accompanyingdrawings, in which is shown an apparatus adapted for the carrying on of the improved process and in Which- Figure l is a plan view of a cement making apparatus adapted for the practice of the invention. Fig. 2 is a view thereof in side elevation. Fig. 3 is a partial end elevation.

I n this showing a is a rock crusher of an ordinary type delivering crushed material into a suitable receptacle whence it is removed by conveyer b and transferred to chute b1, whence it passes through b2 into a calcining kiln c. Thev calcining kiln is provided at its upper end with a dust chamber c1 communicating with stack 02. At the lower end this kiln is providedwvith a stationary housing c3 of an ordinary type. A battery of gas producers (l communicating With gas line d* feeds gas burner d? passing through the housing and into the mouth ofl the kiln. The calcined material falls through the housing in the usual manner into cooler e and thence into a calcines pit e1. Air passing up through the cooler e and through the housing, is heated by the calcines and serves to aid in the combustion of the fuel burning in the mouth of the kiln. The calcined material is removed by conveyer to regrinding means f1. F rom the regrin ing means, the fine material is taken by hopper g and conveyers h and 2 into the up er end of a similar kiln k. At its upper en this kiln enters a dust chamber k1 communicating with stack k2. The calcined fine ground material passing, down vthrough c is heated by a.

flame from gas burner da entering through a stationary housing in the mouth of the kiln in the same manner as in the rst kiln.` lThe clinkered material passes downward through the housing into another cooler Z (shown in Fig. 1` in dotted lines and similar to the cooler shown in Fig. 2). Air, passes up through this clinker cooler', aiding in the cooling of the clinker' and the combustion of the gas fiamein the mouth of the kiln.

In the operation with the described appa- 'rat-us the raw material, whether it be limestone, or cement rock, or a mixture of both,`

or any other cement making material in relatively large and hard masses, is first reduced to a coarsely crushed condition, as by the stone crusher a, so that it will be in suitable 4condition for subjection to the next -step of the process and is then progressively calcined, by its passage through the rotary kiln c, to a degree sufficient to drive 0H moisture and/carbonic acid gas and thereby to make it porous and friable. The crushing and the preliminary calcining are suc- .end of the kiln and the flame and flame gases acting upon .the material progressively as it passes from the upper to the lower end. After the preliminary calcination the material is preferably cooled, as by passage through the cooler e and is immediately and continuously reduced to a finely divided con- ,dition as by the mill g to which, in the apparatus shown, the partially calcined material is delivered by the elevator f. By reason of the porous and friable condition of thc calcined material. the regrinding is .easily and quickly effected, with a mill of simple and inexpensive-coustruction and with consumption of but little power. As the material is` reduced to a finely divided condition it is immediately and progressively heated, as in the second rotary kiln la, to a degree sufiiciently high to eflect combination of the constituents or clinkering, the finely divided material from the regrinding mill g being delivered to the second rotary kiln k, in the apparatus show-n, by the conveyer h and the elevator z'. After clinkering the material is cooled, as in the cooler Z, and is then pulverized or is stored as clinker to be pulverized later.

If the limestone and cement rocks, or other V"hard material, are not mixed before crushing and the first burning. they may be mixed immediately after the first burning, each ma'- terial being progressively and partiallyl calcined as above described` and the two materials being mixed after the partial calcination. I t' comparatively pure limestone rock and clay are the materials employed, the limestone rock is crushed and partially calcined as already described and the clay is then mixed with it, as at fl.

' The temperature maintained during the preliminary calcinatioli, as already indicated,

terials employed.

ing. The reduction in the weight ofthe mai 'the handling of about one-third of the Awhich the material is subjected throughout of mechanical poWer required to effect such `limestone and cement rock 1'is very great.l

yWithout a' great expenditure of power. Furthermore, the carbonlc acid gas is or may ,aaams is merely suflicient to drive off all or nearly all of thecarbonic acid gas and the moisture, being from 800o C.. to 1000o C. according to the materials used. The individual firing means for: this kiln permits suitable adjustments of thermal conditions Within thekiln. The temperature maintained during the final burningis high enough to eect com-v bination or clinkering, being usually from 1500o C. to 1800 `C.'according to the ma.-

`It is to be observed that the treatment tto the process is continuous and progressive, each step onstage 'following immediately upon another, Without intermission or manual -haiidlin of the materials.

By the practice of the improved process the materials are rendered friable before any ,fine grinding is required, so that the amount grinding is enormously reduced, being only about ten per cent. of that required in the ordinary'` process of making cement. y The power required for making an impalpable and .uniform powder of such very hard materials as .But upon calcining these materials they are cracked and shattered and are rendered intimately porous and friable by the expulsionof carbon dioXid throughout their mass and are then easily comminuted to any degree be completely driven off in the preliminary calcination, before the regrinding, so that it is not necessaryto drive off carbonio acid gas iii the secondary or final burning or clinkerteral required, to be handled in the grinding is Vlikewise considerable, the' material required for the manufact-ure of one' barrel of cement (380 pounds) by the old process being from 630 to 650 pounds, all ofvvhich must be' carried through all the preliminary stages of drying, crushing and grinding, While the weight of calcined'niaterial necessary for the manufacture of one barrel of cement which must be fine-ground by the improved process is from 380 to 400 pounds,

Weight of material prior to fine grinding being thus avoided.

As the calcines leave the preliminary kiln, they are very hot and it is desirable to cool them down to enable the use of simple types of grinding mechanism. .This cooling hoW- ever'is of course attended with a loss of heat which lwould militate against the economy of the process if it were not restored `tothe kiln.. But by runnin the vhot calcines through the rotary coo ere, airutaken upward therethrough by the kiln draftv at the heatabsorbed from the calcinesto the kiln.y

It will be understood that the improved process herein described is independent of any particular form vof mechanism, that illustrated in the accompanying drawings and referred to-herein being merely a convenient form. 9

vvWe claim as our invention: `1. The cement making process which comprises coarsely crushing raw cement material, continuously calcining said crushed material in a rotary kiln, cooling said calcined material in a rotary cooler and thereby heating a supply o'f air to aid combustion in said kiln, finely grinding and mixing said calcined material, continuously feeding the same through a rotary clinkering kiln, said kiln being heated to clinkering temperature by a producer gas flame moving in the opposite direction to the feed of material, and ccoling the clinkered material in a rotary cooler and thereby heating a supply of air to aid combustion in said cliiikering kiln.

2. The cement making process 'which com-` prises coarsely crushingraw cement mate:

rial, continuously calcining said crushed material in a'rotary kiln, cooling said calcined materialand thereby heating air to aid in combustion in said kiln, finely grinding and mixing said calcined material, continuously feeding the same through a rotary clinkering kiln, said kiln being heated to a clinkering temperature by, a heating flame moving inthe opposite direction to the' feed ofmaterizl through said kiln and cooling the clinkered material and thereby heating vair to aid .in combustion in sald-clmkering kiln.

3. The cement making process which coml prises' coarsely crushing raw 'cement material, continuously calcining said crushed material in a rotary kiln and thereby rendering the said material porous and friable, cooling 'said calcined material and thereby heating air to aid in combustion in said kiln, finely grinding and mixing said calcined material, and thereupon continuously feeding the samev through a rotary clinkering kiln, and heating said clinkering kiln to cement clinkering temperatureby a fuel flame supported by preheated air.

4. The cement making process which comprises continuously calcining cement material in a rotary kiln heated to calcining-teniperature, grinding the calcined material and feeding .sai'd ground calcined material through a clinkeringkiln heated to clinkering temperature `by a heating iame supported by preheated airfed to said kiln.

5. The continuous process of making cementclinker comprising passing raw cement material through a. primary rotary kiln, then pulverizing said materials, thenv pass- 'isc and expelling carbon-dioxid from ing'said pulverized material througha secondary rotary kiln, and during the passage of the materials through said kilns in continuons succession, clinkering the pulverized material in the secondary kiln, and driving the carbon-dioxid from the raw material in the primary kiln.

'6. The 'process ot producing cement clinker which comprises crushing cement materials, calcining the saine, cooling the calcines and restoring their heatto the calcining means, regrinding the cool calcines and clinkering the reground calcines.

7. The cement making process which comprises coarsely crushing cement material, passing the crushed material through a ro tary kiln heated to calcining temperature the crushed material in transit therethrough, then grinding the material and passing the 4ground material through a clinkering kiln heated 4to clinkering temperature. l

8. The cement making process which comprises continuously calcining cement material in a rotary kiln heated to calcining teniperature, grinding the calcined material and feeding said ground calcined material through a c linke-rii/ig kiln heated to clinkering temperature.

S). The process of making cement clinker which comprises passing cement materials as a continuously traveling stream through a succession of rotary kiln sections, one such section being adapted for calcining and another forclinkering and diverting the stream intermediate such kiln sections through regrinding means.

10. The process of making cement clinker which comprises passing cement materials continuously through successively operating4 conditions appropriate for clinkering, and" diverting said stream intermediate said kiln sections through regrinding means.

This specification signed and witnessed this twenty eighth day of September, A. D.,

R. W. LESLEY. HENRY S. SPACKMAN. Signed in the presence of- J. F. LnNNio, WM. Loro, Jr. 

